A sheet metal

Abstract

A sheet metal (100) with array of non-rectilinear corrugation is disclosed. The pattern is such that it comprises a first and second array of non- rectilinear corrugation (A1, A2) that meet at a line (Y) of the sheet metal (100). The array of non-rectilinear corrugation (A1, A2) have alternating crest (C), trough (T) and a pitch (P) between consecutive crest (C) or consecutive trough (T) and each non-rectilinear corrugation in the first and second array of non-rectilinear corrugation (A1, A2) meets the line (Y) forming an U-shape. The non-rectilinear corrugations (A1, A2) are aligned with a straight line (X) such that every crest (C) and trough (T) lie on the straight line (X) wherein an angle Z and Z' ranging from 76-85 degrees is formed between the line X of one non-rectilinear corrugation in the first set and second set and the line (Y), respectively. The sheet metal (100) thereafter can be formed into reinforced drywall construction element (200) which can be used as a drywall stud or ceiling cannel or floor channel.

Description

[0001] A SHEET METAL

[0002] Technical Field

[0003] The present disclosure relates, in general to a sheet metal, and specifically to a reinforced sheet metal, and more specifically to sheet metal with an array of non-rectilinear corrugation for dry wall stud or and ceiling channel. More specifically, the present disclosure relates to a sheet metal with two arrays of non-rectilinear corrugations across the surface of the sheet metal.

[0004] Background

[0005] In the building industry, it is widely prevalent to make walls and ceilings from plasterboard, wherein the plasterboards are supported on a framing structure which is provided by studs and channels. The studs and channels are generally formed from sheet metal which provides dimensional stability, durability and ease of manufacturing, among other advantages. Keeping cost cutting a prime objective, the usage of thin metal sheet for the formation of studs and channels is very common in recent times. But there are several drawbacks of using thin sheet metals, including reduced strength and stiffness and higher sound transmission.

[0006] Thus, to further build on the advantages of using thin sheet metals for stud and channel formation, stiffness improvement has been a prime focus. Reinforced metal sheets are known to be an effective way of reducing material gauge while enhancing the performance of the product. The other associated advantages of reinforcement are higher screw retention, higher strength and stiffness due to the increased effective thickness of the sheet metal as well as improved load resistance. Reinforcement is attained by intermeshing reinforced rollers, which preferably have an involute toothing or have a similar toothing and using these rollers to cold roll metal.

[0007] The advantages of reinforced metal sheets can be optimized through the design of the pattern, the positioning as well as dimensional features. For example, in the prior US 2009 / 0038255A1, there is a presence of continuous longitudinal linear reinforcement in the webs which helps in improved screw retention as well as helps in sound insulation. Nevertheless, due to the presence of reinforcement only in a part of the sheet metal, the same would involve manufacturing complexity as well as lower stability as compared to any sheet metal having all-over reinforcement.

[0008] It is observed in the prior art, that rectilinear, yet angular reinforcement of construction profiles, as in the prior art US20200087913A1 has improved screw retention, strength and also withstands quality issues such as waviness, twisting and bending of the construction profile. However, the angular pattern of reinforcement, meeting at the center of the web is more susceptible to cracks. Additionally, there is a screw slippage tendency during the self-drilling process due to angular pattern of reinforcement.

[0009] Thus, there has been a need for non-rectilinear pattern of reinforcement which would not only have the ease of manufacturing, but also would have crack resistance, higher screw retention capacity as well as improved stiffness.

[0010] Based on the above-mentioned requirements, the prior art US20090092798A has been observed to have non-rectilinear reinforcement extending all across the metal sheet. In this case an increased manufacturing difficulty is offset by increased stiffness, however there is a still an existing problem with screw retention. Even though the reinforcing pattern in the prior art is non-rectilinear, screw slippage would still occur with this prior art pattern.

[0011] Thus, there is still need in the art to develop an improved reinforcement for sheet metal - which would thereafter be formed into studs or channels, having ease of manufacturability, higher stiffness, improved screw retention and gripping capacity, reduced flange bending and improved load resistance.

[0012] Hence, the objective of the present disclosure is to provide a sheet metal having non-rectilinear reinforcement having angularities involved in the pattern. This pattern improves screw retention and twist resistance. Further, the pattern of reinforcement as in the present disclosure can resist various types of incoming dynamic loads - including flange bending which is yet another objective of the present disclosure. Summary of the Disclosure

[0013] In one aspect of the present disclosure, a sheet metal is disclosed. The sheet metal comprises: a first array of non-rectilinear corrugation and a second array of non-rectilinear corrugation. Each non-rectilinear corrugation in the first and second array of non-rectilinear corrugation meet at a line (Y) drawn parallel to a principal axis of the sheet metal. Further, each non-rectilinear corrugation in the first and second array of non-rectilinear corrugation have alternating crest (C), trough (T) and a pitch (P) between consecutive crest or consecutive trough, where the crest (C) and trough (T) are defined in the plane of the sheet. Each non- rectilinear corrugation in the first and second array of non-rectilinear corrugation (Al, A2) meets the line (Y) forming an U-shape. Further, each non-rectilinear corrugation is aligned with a straight line (X) such that every crest (C) and trough (T) lie on the straight line (X). The straight line (X) for each corrugation in the first set of non-rectilinear corrugations meets the line (Y) at an angle (Z) ranging from 76-87 degrees. Similarly, the straight line (X) for each corrugation in the second set of non-rectilinear corrugations meets the line (Y) at an angle (Z1) ranging from 76-87 degrees.

[0014] In another aspect of the present disclosure, a reinforced drywall construction element formed with the sheet metal is disclosed. The reinforced drywall construction element comprises: two parallel spaced apart flange members and a central web member bridging the flange members. At least one of the web members or the flange members comprise a first and a second array of non- rectilinear corrugations, and the flange members raise from the web member at a crest or a trough of the first and second array of non-rectilinear corrugations.

[0015] Other features and aspects of this disclosure will be apparent from the following description and the accompanying drawings.

[0016] Brief Description of the Drawings

[0017] Embodiments are illustrated by way of example and are not limited to those shown in the accompanying figures. FIG. 1A illustrates a top view of a sheet metal, according to one embodiment of the present disclosure;

[0018] FIG. IB illustrates an enlarged view of the sheet metal as shown in FIG. 1A;

[0019] FIG. 2 illustrates a cross-sectional view of the sheet metal as shown in FIG. 1A;

[0020] FIG. 3A illustrates a perspective view of a reinforced construction element, according to an embodiment of the present disclosure;

[0021] FIG. 3B illustrates a perspective view of a reinforced construction, according to another embodiment of the present disclosure;

[0022] FIG. 4 illustrates an apparatus for forming a sheet material, according to one embodiment of the present disclosure;

[0023] FIG. 5 illustrates a perspective view of a drywall partition framing assembly in accordance with one embodiment of the present disclosure.

[0024] Skilled artisans appreciate that elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale. For example, the dimensions of some of the elements in the figures may be exaggerated relative to other elements to help to improve understanding of embodiments of the disclosure.

[0025] Features and advantages of the present disclosure will become more apparent in light of the following detailed description of embodiment, as illustrated in the accompanying figures. As will be realized, the disclosure is capable of modifications in various respects, all without departing from the present disclosure. Accordingly, the drawings and the description are to be regarded as illustrative in nature, and not restrictive.

[0026] Detailed Description

[0027] Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or similar parts. Hereinafter, exemplary embodiments of the present disclosure will be described in detail with reference to the accompanying drawings. As used throughout, a “U-shaped” construction element is defined as a construction element comprising a pair of flanges substantially parallel to each other and connected substantially perpendicularly at their base by a web.

[0028] As used throughout, a “C-shaped” construction element is defined as a construction element comprising a pair of flanges substantially parallel to each other and connected substantially perpendicularly at their base by a web, with the pair of flanges having return edges pointing inwards substantially parallel to the web.

[0029] FIG. 1 illustrates a top view of a sheet metal (100), in accordance with one embodiment of the present disclosure. The sheet metal (100) comprises a first array of non-rectilinear corrugations (Al) and a second array of non-rectilinear corrugations (A2). Each of the non-rectilinear corrugation in the first and second array of non-rectilinear corrugation (Al, A2) meet at a line (Y) drawn parallel to a principal axis (L) of the sheet metal (100). In a preferred embodiment, the line (Y) is a line, but in other embodiments, it can be any line parallel to principle axis (L). Further, each non-rectilinear corrugation in the first and second array of non- rectilinear corrugation (Al, A2) have alternating crest (C), trough (T) and a pitch (P) between consecutive crest (C) or consecutive trough (T) as can be clearly understood from FIG. IB which depicts an enlarged view of the sheet metal as shown in FIG. 1A.

[0030] Each non-rectilinear corrugation in the first and second array of non-rectilinear corrugation (Al, A2) meets the line (Y) forming a U-shape. The U- shape reduces the local stress concentration on the sheet metal (100) during the corrugation formation, thus resulting in lower chances of breakage or deformation along the line (Y). Further, each non-rectilinear corrugation in the first and second array of non-rectilinear corrugations (Al, A2) is aligned with a straight line (X) such that every crest (C) and trough (T) lie on the straight line (X) and the straight line (X) meets the line (Y) at an angle (Z, Z’) ranging from 76-87 degrees. In some of the embodiments, the angle Z and Z’ can be from 78-82 degrees or alternatively the angle Z and Z’ can be 87 degrees based on the requirements. In all the embodiments, the angle (Z), pitch (P), U-shape where the non-rectilinear corrugation (Al, A2) meet are independent of the positioning of the line (Y).

[0031] The first and second array of non-rectilinear corrugations (Al, A2) are sinusoidal or serpentine or zig-zag. In some other embodiments, there can be any other form of non-rectilinear reinforcing pattern as well. These arrays of non- rectilinear corrugations provide increased strength, stiffness, improved screw retention and reduced flange bending. Further, the first and second array of non- rectilinear corrugations (Al, A2) forms U-shape with the line (Y). These first and second array of non-rectilinear corrugation (Al, A2) are formed on both front and back surface of the sheet metal (100). But, in some other embodiments, these first and second array of non-rectilinear corrugation (Al, A2) are formed only on one surfaces of the sheet metal (100).

[0032] There is a pre-defined spacing between each of the non-rectilinear corrugations in the first and second array of non-rectilinear corrugation (Al, A2). The spacing is such that it ensures that the first and second array of non-rectilinear corrugation (Al, A2) cover a surface area of 25% to 75% of the sheet metal (100) area. In some other embodiment, the first and second array of non-rectilinear corrugation (Al, A2) covers 50% to 75% of the sheet metal (100) area. Here the surface area of the sheet metal covered by the first and second array of corrugations is defined as the surface area where the sheet metal has been deformed out of the original plane of the metal.

[0033] The pitch (P) between consecutive crests (C) or consecutive troughs (T) in multiple embodiments of the present disclosure ranges between 6 mm and 12 mm. In some of the embodiments, a distance between two consecutive crest (C) is equal to a distance between two consecutive troughs (T). The crest (C) and trough (T) of the first and second array of non-rectilinear corrugation (Al, A2) is curved or flat in more than one embodiment of the present invention.

[0034] FIG. 2 illustrates a cross-sectional view of the sheet metal as shown in FIG. 1A. The ridges of the first and second array of non-rectilinear corrugations (Al, A2) form depressions (D) and projections (J) on the front and back surfaces of the sheet metal, according to the embodiment illustrated in Fig. 2. Alternatively, in other embodiments of the present invention, the ridges of the first and second array of non-rectilinear corrugations (Al, A2) form either depressions or projections on only one of the two surfaces of the sheet metal. The projections (J) and depressions (D) of the first and second array of non-rectilinear corrugation (Al, A2) is curved or flat according to multiple embodiments of the present invention. Further, an effective thickness (te) of the sheet metal (100) is at least twice the thickness (t) of the sheet metal (100). This increased effective thickness (te) results in higher sound insulation properties and thus overall acoustic performance is enhanced. The usual thickness (t) of the sheet metal (100) ranges from 0.3 to 2 mm.

[0035] FIG. 3A, illustrates a perspective view of a reinforced construction element (200), according to an embodiment of the present disclosure. The reinforced construction element (200) is formed with the sheet metal (100) and comprises - a web member (10) and a first and second flange members (20) rising at an angle ranging from 90° to 110° from the web member (10). In the present embodiment, the web member (10) comprises a first and a second array of non-rectilinear corrugation (Al, A2), as well as the first and second flange members (20) comprise a first and a second array of non-rectilinear corrugation (Al, A2). In another embodiment, as depicted in FIG. 3B, only the web member (10) comprises a first and a second array of non-rectilinear corrugations (Al, A2), while the first and second flange members (20) are devoid of corrugations. In some other embodiment (not shown in the figures), the first and the second array of non- rectilinear corrugation (Al, A2) meet at a point on at least one flange member (20) and the web member (10) is devoid of corrugations. In some embodiments (not shown in the figures), the first and second array of non-rectilinear corrugations (Al, A2) meet at the mid-point on at least one flange member (20) and the web member (10) is devoid of corrugations. In any of the cases, for all the embodiments, the first and second flange (20) raises from the web member at a crest (C) or a trough (T) of the first and second array of non-rectilinear corrugation (Al, A2) - which is present either across the entire surface of web (10) and the first and second flange member (20) or is present only across the surface of the web (10) . The embodiments as depicted in FIGs. 3A and 3B are used either as drywall stud or ceiling channel or as floor channel.

[0036] Further, in any of the embodiments as depicted in FIGs. 3A and 3B, there can be a flat portion - which is devoid of reinforcement and is used to emboss a trademark, a name of a product or other information related to the reinforced construction element (not in FIG.).

[0037] For the reinforced construction element, in one embodiment, the first flange member (20) has height same as the second flange member (20). While in any other embodiment, the first flange member (20) has height different from the second flange member (20) (not in FIG.). In one embodiment, as in FIG. 3A, the first and second flange member terminate with inwardly pointing return edge (30), wherein the return edge overlie the web member (10) and is parallel to the web member (10) - thus resulting in a C-shaped construction element. In another embodiment, the first and second flange member (20) terminate with outward return edges, wherein the outward return edge lies outside the web member (10) and is parallel to the web member - thus resulting in a C-shaped construction element (not in FIG.). For either of embodiments, inward return edge (30) or outward return edge lies at 90° from the first and second flange member (20) and raises from the first and second flange member (20) at a crest (C) or a trough (T) of the first and second array of non-rectilinear corrugation (Al, A2). In yet another embodiment, first and second flange member is without return edges - thus resulting in a U-shaped construction element (not in FIG.).

[0038] The present invention further discloses an apparatus comprising a pair of rollers 610 and 620 for making the sheet metal (100) illustrated in FIG. 1A. FIG. 4 illustrates the apparatus (600) according to one embodiment of the present invention. The apparatus 600 comprises a first roller 610 and a second roller 620 that mate with each other contra rotating about their respective axes. The first roller 610 comprises a first non-rectilinear corrugation region 630a and a second non- rectilinear corrugation region 640a. The first non-rectilinear corrugation region 630a forms one part of the first array of non-rectilinear corrugations AU and the second non-rectilinear corrugation region 640a forms one part of the second array of non-rectilinear corrugations A2’.

[0039] The second roller 620 comprises a third non-rectilinear corrugation region 630b and a fourth non-rectilinear corrugation region 640b. The third non- rectilinear corrugation region 630b forms the other part of the first array of non- rectilinear angular corrugations Al” and the fourth non-rectilinear corrugation region 640b forms one part of the second array of non-rectilinear corrugations A2”. The first non-rectilinear corrugation region 630a and third non-rectilinear corrugation region 630b are co-operable. Similarly, the second non-rectilinear corrugation region 640a and fourth non-rectilinear corrugation region 640b are cooperable.

[0040] The first array of non-rectilinear corrugation (AT, Al”) meet the second array of non-rectilinear corrugation (A2’, A2”) at a line (Y) drawn parallel to a principle axis (L) of the sheet metal (100) forming a U-shape.

[0041] In an alternate embodiment, the first roller 610 and second roller 620 may have multiple sets of first, second, third and fourth non-rectilinear corrugation regions (630a, 630b, 630c etc., and 640a, 640b, 640c etc.,).

[0042] In an alternate embodiment, the first roller 610 and second roller 620 may have multiple sets of first, second, third and fourth non-rectilinear corrugation regions (630a, 630b, 640a and 640b). For example, a first roller and a second roller comprising three sets of first, second, third and fourth non-rectilinear corrugation regions viz., 630al, 630bl, 640al and 640bl; 630a2, 630b2, 640a2 and 640b2; and 630a3, 630b3, 640a3 and 640b3 would produce a sheet metal with three pairs of non-rectilinear corrugation arrays (Al and A2, Ala and A2a, Alb and A2b). When bent into shape, such a sheet metal would have three pairs of non- rectilinear corrugation arrays such that one pair (Al and A2) is on the base profile, one pair (Ala and A2a) is on the first leg profile and one other pair (Alb and A2b) on the second leg profile.

[0043] The pair of rollers 610 and 620 stretch the sheet material angularly and effectively increases (doubles) the thickness of the sheet material. FIG 5 of the present disclosure illustrates a perspective view of a drywall partition framing assembly (1000) in accordance with one embodiment of the present disclosure. The partition framing assembly (1000) is formed of a plurality of reinforced construction element (200) formed from the sheet metal (100) which includes drywall studs as well as channels - both floor as well as ceiling channel. A floor channel (400) is fixed to a floor and a ceiling channel (450) fixed to a ceiling and are placed parallelly and spaced at a distance from each other. A plurality of drywall studs (200) are spaced vertically and mounted to the floor and ceiling channels (400, 450). Further, the partition board (300) is mounted such that they are screwed to the studs at the crest (C) or trough (T). The partition boards (300) can be attached to one or both sides in the partition framing assembly (1000). Any suitable fastening mechanisms, for example, screws, adhesives etc. may be used to accomplish the coupling between the studs and the partition boards, as applicable. Further, a suitable jointing method may be used to attach the partition boards (300) to each other.

[0044] The partition boards (300) are generally gypsum boards. The partition board (300) may be reinforced and may include a polymeric binder and a plurality of fibres. The plurality of fibres may include glass fibres, synthetic polymer fibres or natural fibres, either separately or in combination. Further, the polymeric binder may include any of starch, synthetic material etc. In various other embodiments, the partition board (300) may include any other materials such as, but not limited to, MDF, plywood, glass, metal sheet, cement, fiber cement, plastic sheet or a combination thereof.

[0045] The partition board (300) may also include a subsequently placed one or more layers of insulation elements (not shown). The insulation element may include a foam material or other materials to provide any of acoustic properties, strength or other properties to the drywall partition system. Alternatively, the drywall partition system (1000) may be configured without the insulation element. Various parameters related to the reinforced construction elements, such as, a number of the reinforced construction element in the partition framing assembly, the width of the reinforced construction element, vertical length of the reinforced construction element, cross-section of the reinforced construction element, spacing of the reinforced construction element may suitably vary based on the type of application. For example, the parameters related to the reinforced construction elements may depend on the size of the partition board required for the application, strength of the partition board etc.

[0046] Comparative Example

[0047] Simulations of deflection under lateral load condition were compared for a conventional construction element, a reinforced construction element with linear-yet angular reinforcement, and the construction elements described above. In the simulation, a load of 50 N was applied on one side of one of the flanges of the three construction elements described above. The results are shown in Table 1. The results show that the reinforced construction element of the present disclosure has least deflection value and hence is stronger.

[0048] Table 1 : Deflection under Lateral Load Condition

[0049] Industrial Applicability

[0050] Thus, the usage of the sheet metal for the construction elements like studs or ceiling channel or floor channel, results in improved screw retention property of the construction elements. In addition, the reinforced sheet metal possesses the following advantages:

[0051] Improved load resistance of the reinforced construction elements formed of the sheet metals (100),

[0052] - Reduced deflection due to incoming load, Reinforcing pattern stiffens the material utilized in forming the reinforced construction element - it thereby helps reduce the flange bending, Improved sound insulation due to the increased effective thickness - thus resulting in acoustic comfort,

[0053] The array of angular patterns being present all over the sheet metal reduced the manufacturing complexity - thus resulting in economic benefits.

[0054] Having thus described the disclosure with particular reference to the preferred forms thereof, it will be obvious that various changes and modifications can be made therein without departing from the spirit and scope of the present disclosure as defined by the appended claims. Such changes and modifications include combinations of compatible features from different embodiments of the present disclosure. Therefore, the embodiments described in the specification and the drawings shown in the drawings are only the most preferred embodiment of the present disclosure and do not represent all of the technical ideas of the present disclosure, various modifications that can be replaced at the time of the present application It should be understood that there may be equivalents and variations.

[0055] Note that not all of the activities described above in the general description or the examples are required, that a portion of a specific activity may not be required, and that one or more further activities may be performed in addition to those described. Still further, the order in which activities are listed is not necessarily the order in which they are performed.

[0056] Benefits, other advantages, and solutions to problems have been described above with regard to specific embodiments. However, the benefits, advantages, solutions to problems, and any feature(s) that may cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as a critical, required, or essential feature of any or all the claims.

[0057] The specification and illustrations of the embodiments described herein are intended to provide a general understanding of the structure of the various embodiments. The specification and illustrations are not intended to serve as an exhaustive and comprehensive description of all of the elements and features of apparatus and systems that use the structures or methods described herein. Certain features, that are for clarity, described herein in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features that are, for brevity, described in the context of a single embodiment, may also be provided separately or in a sub combination. Further, reference to values stated in ranges includes each and every value within that range. Many other embodiments may be apparent to skilled artisans only after reading this specification. Other embodiments may be used and derived from the disclosure, such that a structural substitution, logical substitution, or another change may be made without departing from the scope of the disclosure. Accordingly, the disclosure is to be regarded as illustrative rather than restrictive.

[0058] The description in combination with the figures is provided to assist in understanding the teachings disclosed herein, is provided to assist in describing the teachings, and should not be interpreted as a limitation on the scope or applicability of the teachings. However, other teachings can certainly be used in this application.

[0059] As used herein, the terms "comprises," "comprising," "includes," "including," "has," "having" or any other variation thereof, are intended to cover a non-exclusive inclusion. For example, a method, article, or apparatus that comprises a list of features is not necessarily limited only to those features but may include other features not expressly listed or inherent to such method, article, or apparatus. Further, unless expressly stated to the contrary, "or" refers to an inclusive-or and not to an exclusive-or. For example, a condition A or B is satisfied by any one of the following: A is true (or present) and B is false (or not present), A is false (or not present) and B is true (or present), and both A and B are true (or present).

[0060] Also, the use of "a" or "an" is employed to describe elements and components described herein. This is done merely for convenience and to give a general sense of the scope of the disclosure. This description should be read to include one or at least one and the singular also includes the plural, or vice versa, unless it is clear that it is meant otherwise. For example, when a single item is described herein, more than one item may be used in place of a single item. Similarly, where more than one item is described herein, a single item may be substituted for that more than one item.

[0061] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. The materials, methods, and examples are illustrative only and not intended to be limiting. To the extent that certain details regarding specific materials and processing acts are not described, such details may include conventional approaches, which may be found in reference books and other sources within the manufacturing arts.

[0062] While aspects of the present disclosure have been particularly shown and described with reference to the embodiments above, it will be understood by those skilled in the art that various additional embodiments may be contemplated by the modification of the disclosed machines, systems and methods without departing from the spirit and scope of what is disclosed. Such embodiments should be understood to fall within the scope of the present disclosure as determined based upon the claims and any equivalents thereof.

[0063] List of Elements

[0064] TITLE: A SHEET METAL

[0065] 10: Web Member

[0066] 20: First and Second Flange Member

[0067] 30: Inward Return Edge

[0068] 100: Sheet Metal

[0069] 200: Reinforced Construction Element

[0070] 300: Partition Board

[0071] 400: Floor Channel

[0072] 450: Ceiling Channel

[0073] 1000: Drywall Partition Framing Assembly

[0074] Al : First Array of Non-Rectilinear Corrugation

[0075] A2: Second Array of Non-Rectilinear Corrugation

[0076] C: Crest

[0077] L: Principal Axis t: Thickness te: Effective Thickness

[0078] T: Trough

[0079] P: Pitch

[0080] X: Line

[0081] Y : Line

[0082] Z, Z’: Angle

[0083] D: Depression

[0084] J: Projection

Claims

ClaimsWe Claim:

1. A sheet metal (100), comprising: a first array of non-rectilinear corrugation (Al) and a second array of non-rectilinear corrugation (A2), with each non-rectilinear corrugation in the first and second array of non-rectilinear corrugations (Al, A2) meeting at a line (Y) drawn parallel to a principle axis (L) of the sheet metal (100), wherein, each non-rectilinear corrugation in the first and second array of non-rectilinear corrugation (Al, A2) have alternating crest (C), trough (T) and a pitch (P) between consecutive crest (C) or consecutive trough (T), wherein each non- rectilinear corrugation in the first and second array of non-rectilinear corrugation (Al, A2) meets the line (Y) forming an U-shape and, wherein the non-rectilinear corrugations are aligned with a straight line (X) such that every crest (C) and trough (T) lie on the straight line (X) and meets the line (Y) at an angle Z and Z’, respectively ranging between 76 and 87 degrees.

2. The sheet metal (100) as claimed in Claim 1, wherein the first and second array of non-rectilinear corrugation (Al, A2) are sinusoidal or serpentine or zigzag.

3. The sheet metal (100) as claimed in Claim 2, wherein the first and second array of non-rectilinear corrugation (Al, A2) forms U-shape with the line (Y).

4. The sheet metal (100) as claimed in Claim 1, wherein the ridges of the first and second array of non-rectilinear corrugations (Al, A2) form depressions (D) and projections (J) on at least one of the front and back surfaces of the sheet metal.

5. The sheet metal (100) as claimed in Claim 4, wherein the Projection (J) and Depression (D) of the first and second array of non-rectilinear corrugation (Al, A2) is curved or flat.

6. The sheet metal (100) as claimed in Claim 1, wherein a thickness (t) of the sheet metal ranges from 0.3 - 2 mm.

7. The sheet metal (100) as claimed in Claim 1, wherein an effective thickness (te) of the sheet metal (100) is twice the thickness (t) of the sheet metal (100).

8. The sheet metal (100) as claimed in Claim 1, wherein the pitch (P) ranges between from 6mm to 12mm.

9. The sheet metal (100) as claimed in Claim 1, wherein the first and second array of non-rectilinear corrugation (Al, A2) cover a surface area of 25% to 75% of the sheet metal (100).

10. The sheet metal (100) as claimed in Claim 1, wherein a distance between two consecutive crests (C) is equal to a distance between two consecutive troughs (T).

11. The sheet metal (100) as claimed in Claim 1, wherein the first and second array of non-rectilinear corrugation (Al, A2) are formed on both front and back surface of the sheet metal (100).

12. A reinforced drywall construction element (200) formed from the sheet metal (100) as claimed in Claim 1, wherein the construction element (200) comprises two parallel spaced apart flange members (20) and a central web member (10) bridging the flange members (20) wherein at least one of the web member (10) or the flange members (20) comprise a first and a secondarray of non-rectilinear corrugation (Al, A2), and wherein, the flange members (20) raise from the web member (10) at a crest (C) or a trough (T) of the first and second array of non-rectilinear corrugation (Al, A2).

13. The reinforced dry wall construction element (200) as claimed in Claim 12, wherein the flange members (20) have a height same as or different from each other.

14. The reinforced drywall construction element (200) as claimed in Claim 12, wherein, the flange members (20) may optionally terminate with inwardly pointing return edge (30), wherein the return edge (30) overlie the web member (10) and is parallel to the web member (10).

15. The reinforced dry wall construction element (200) as claimed in Claim 12, wherein, the flange members (20) may optionally terminate with outward return edges, wherein the outward return edge lies outside the web member (10) and is parallel to the web member (10).

16. The reinforced drywall construction element (200) as claimed in Claim 14 or Claim 15, wherein the inward return edge (30) or outward return edge lies at an angle ranging between 10° to 100° from the flange members (20).

17. The reinforced drywall construction element (200) as claimed in Claim 16, wherein the inward return edge (30) or outward return edge raises from the flange members (20) at a crest (C) or a trough (T) of the first and second array of non-rectilinear corrugation (Al, A2).

18. The reinforced drywall construction element (200) as claimed in Claim 12 is a drywall stud or a ceiling channel or a floor channel.

19. An apparatus (600) for forming a sheet metal (100) as claimed in claim 1, the apparatus (600) comprising: a first roller (610) comprising a first non -rectilinear corrugation region 630a for forming one part of a first array of non-rectilinear corrugation (Al’) and a second non-rectilinear corrugation region 640a for forming one part of a second array of non-rectilinear corrugation (A2’); and a second roller (620) comprising a third non-rectilinear corrugation region 630b for forming the other part of the first array of non-rectilinear corrugation (Al ”); and a fourth non-rectilinear corrugation region 640b for forming the other part of the second array of non-rectilinear corrugation (A2”), wherein the first array of non-rectilinear corrugation (AT, Al”) meet the second array of non-rectilinear corrugation (A2’, A2”) at a line (Y) drawn parallel to a principle axis (L) of the sheet metal (100) forming a U-shape.

20. The apparatus (600) as claimed in claim 19, wherein the first roller 610 and second roller 620 are configured to mate with each other.

21. The apparatus (600) as claimed in claim 19, wherein the first and third non- rectilinear corrugation region (630a, 630b) are co-operable and wherein the second and fourth non-rectilinear corrugation region (640a, 640b) are cooperable.- 20 -

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